Apparatus for casting panels



Oct. 16,- 1962 J. P. woGuLls ETAL 3,058,190

APPARATUS FOR CASTING PANELs ik! u.

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APPARATUS FOR CASTING PANELS 5 Sheets-Sheet 2 Filed Jan. l2, 1959 l i l l m /A mtl-@fs i -/ZO Oct. 16, 1962 J. P. woGULls l-:TAL 3,058,190

APPARATUS FOR CASTING PANELS Filed Jan. l2, 1959 5 Sheets-Sheet 3 OOOOOOOOOO Gfrceg/ Oct 16, 1962 J. P. woGULlS ErAL 3,058,190

APPARATUS FOR CASTING PANELS Filed Jan. l2, 1959 5 Sheets-Sheet 4 Ccrefzce @Mar-36, gf

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APPARATUS FOR CASTING PANELS Filed Jan. l2, 1959 5 Sheets-Sheet 5 fj f 55%@ Cofer-cce Marzi/,jf

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Unit Staes This invention relates generally to apparatus for casting panels comprising a plurality of structural building units such as brick spaced apart in parallel relation in a row and secured together by a suitable bonding material with at least one face of the units exposed. More particularly, the invention relates to casting apparatus having rails engageable with opposite ends of the units and co-operating with inatable sealing means to confine the ow of the bonding material and keep the same away from the exposed faces of the units.

The primary object of the invention is to provide improved casting apparatus of the above character which is easy to clean, is readily adaptable to the casting of building units of diierent sizes, and may be used to cast a plurality of panels simultaneously.

Another object is to provide novel inflatable sealing means facilitating the cleaning of the apparatus and capable of accommodating building units of different sizes easily.

A more detailed object is to provide a novel arrangement of supporting members for the building units and; individual inflatable elements for eifectually sealing against adjacent units while avoiding the collection of dirt and other waste material in the apparatus.

The invention also resides in the novel arrangement of the side rails and actuating mechanism for increasing the production capacity of the apparatus.

Other objects and advantages of the present invention will be apparent from the following description and drawings in which:

FIGURE 1 is a side elevational View of a jig construction embodying the novel features of the present invention;

FIG. 2 is a fragmentary plan view of the jig with the inflatable sealing tubes and the manifold removed;

FIG. 3 is an end view of the jig with a modified arrangement of the side rails;

FIG. 4 is an enlarged fragmentary end view;

FIG. 5 is an enlarged fragmentary plan view;

FlG. 6 is an enlarged plan view with the side rails removed;

FIG. 7 is a fragmentary sectional view taken along the line 7 7 of FIG. 6;

FIG. 8 is a fragmentary side view looking along the line 8 8 of FIG. 7;

FIG. 9 is a fragmentary enlarged plan view similar to FIG. 2 but showing the parts in different positions;

FIGS. l0 and 1l are fragmentary sectional views taken respectively along the lines itl-tti and ll-ii of FIG. 9;

FIG. l2 is a fragmentary sectional view taken along the line 12-12 of FIG. 3;

FIG. 13 is a view similar to FIG. l2 Ibut showing the sealing tubes in deflated condition;

FIG. 14 is a fragmentary perspective view of the finished panel.

The apparatus shown in the drawings to illustrate the present invention is especially adapted for the casting of a building panel 16 (FIG. 14) comprising a plurality of building units such as brick 17 secured together by a grout or other bonding material 18 and having at least their front faces 19 exposed. Generally, the improved "g comprises a framework including longitudinally extending outer channel members 20 and a central I-beam 21 secured together by cross members 22. The framework is mounted on vertical posts 23 through the medium of resilient pads '24 which absorb vibrations of the framework and prevent transmission of the same to the posts. Brick to be cast into a panel are supported with their front faces down on cross members 25 of the framework and co-operate with side rails 26 and sealing means 27 to form an upwardly opening mold for receiving and conning the grout in a liquid form and before it solidiiies.

In accordance with the present invention, the cross members .25 and the sealing means 27 are constructed and arranged in a novel manner to adapt the jig for the brick 17 or other building units 28 (FIG. 5) of different dimensions and to facilitate maintenance of the jig by avoiding the accumulation of dirt or other foreign matter. To these ends, the cross members are formed as thin fiat bars lying in horizontally spaced Vertical planes with their upper edges lying in a common horizontal plane to engage the undersides of the brick and support the same with the spaces between the brick and the bars in registry. The sealing means 27 preventing the downward ow of grout between the spaced brick is in the form of separate tub-ular elements which lie between adjacent bars and are infiatable upwardly into sealing engagement with adjacent edges of adjacent brick and with the rails 26 at opposite ends of the brick.

The supporting `bars 25 in this instance lie across the tops of the channels 20 of the framework (FIGS. 1 and 3) and a spacer plate 29 secured to the top of the I-beam 21 (FIG. 10). The bars are spaced apart by sleeves 30 surrounding bolts 31 which extend normal to the bars and through aligned apertures therein, each bolt in this instance extending through twenty of the bars which thus form one of six such sets of bars. To secure the bars to the channels, L-shaped mounting brackets 32 are welded to the spacer sleeves and bolted to the Channels.

The lateral spacing of the supporting bars 25 is correlated with standard and well-known dimensions of brick and other building units of different sizes as to be readily adaptable for use with the Various sizes. In this instance, the bars are approximately 1/8 of an inch thick and their centers are spaced 1% inches apart. With these dimensions, the bars are adapted to support building units having dimensions based on four inch modules according to the principles of modular construction. Under such principles, each unit has a nominal dimension which is equal to the actual dimension plus the desired thickness of mortar joints between'units` and which are multiples or fractions of the selected module, herein, four inches. For example, the actual height of a brick having a nominal height of two and two-thirds inches is two and onesixth inches where the desired thickness of the mortar joint is one-half of an inch. The position of such a brick relative to two adjacent bars is shown in the lower portion of FIG. 5 and in FIGS. l2 and 13. For a wider building unit such as a tile 28 of four inch nominal and 31/2 inch actual height, the tile spans three supporting bars as shown in the upper portion of FIG. 5.

Being formed as separated tubes, the sealing elements 27 may be disposed only in the spaces between adjacent supporting bars 25 where there are registering spaces between the brick 16 on the bars. In this instance where it is assumed that each brick spans only two bars as shown in FIGS. 12 and 13, the tubes are disposed only in alternate spaces between the bars thereby leaving the intervening spaces free for gravitation dirt and other foreign matter away from the area where the panels are cast. Each tube lies on a cross channel 33 (FIG. 8) resting on the spacer sleeves 30 for the supporting bars. Herein, there are two tubes lying end to end in each of the alternate spaces between the supporting bars with the inner adjacent ends of the tubes closed by suitable clamping means (not shown). The outer ends of the tubes telescope over and are adhesively secured to mounting blocks 34 which are clamped between a manifold 35 and the cross channel 33 by bolts 36, the manifold supplying iluid under pressure to the tubes. The bolts extend through but are smaller than vertical passageways 37 (FIG. 8) which are formed in the blocks and communicate at their upper ends with the interior of the manifold and at their lower ends with horizontal passageways 38 leading int-o the tubes.

The manifold 35 is a hollow metal tube of rectangular cross section `and of U-shape with parallel horizontal legs 39 extending along opposite sides of the jig and connected to the inatable tubes 27 as described above. Herein, holes for attachment of the tubes are formed at every space between adjacent supporting bars 25 even though the tubes are located only in alternate spaces. `At the intervening spaces, suitable seals 40 are clamped against the manifold and around the holes by bolts 41 (lFIG. 4) to prevent the loss of pressure fluid from the manifold, such bolts extending through plates 42 on the undersides of the supporting bars to Secure the manifold to the bars. A suitable fixture (not shown) is mounted `on the closed end 43 of the manifold for the introduction of pressure fluid, herein, air, to the interior of the manifold to inilate the tubes.

To enable a plurality of panels 16 to be cast simulta neously, the `supporting bars 25 are made longer than the width of two panels and there are more than two side rails 26 arranged in pairs and laterally spaced from each other along the bars. Of each pair of rails, at least one is movable toward and away from the other one to clamp against opposite ends of the brick to hold the same rigidly in position during the pouring and hardening of the grout 18 and to release the brick after the grout hardens. As shown in FIG. 1, there may be two pairs of rails for casting two panels at one time or, as shown in FIG. 3, there may be four pairs of rails for the casting of four panels. In both constructions, the inner rails 26 indicated lby the suix a are movable and the outer rails 26 with the suix b are secured in fixed positions on the supporting bars.

In the double panel casting construction of FIG. 1, all of the rails 26a and 2Gb are of L-shaped cross section each with a horizontal leg lying against the tops of the supporting bars 25 and an upstanding leg engageable with the ends of brick on the bars. The upstanding legs may vary in cross sectional shape to provide different contours on the side edges of the finished panels as shown in FIG. l0. The xed outer legs 2Gb may be secured to the supporting bars by any suitable means such as clamps (not shown). To hold the movable rails 26a downwardly against the supporting bars While permitting movement of the rails along the bars, rollers 44 rotatably supported on bolts 45 depending rigidly from these rails engage the undersides of short cross pieces 46 welded to the tops of the center I-beam 21 (FIG. 10).

'Ihe construction and operation of the mechanism for shifting the movable rails 26a back and forth preferably is simplified by utilizing a single actuator 47 (FIGS. 1 and 2) which is linked to both rails to move the same simultaneously. Herein, this mechanism comprises a fluid pressure actuator of the piston and cylinder type having its cylinder 48 secured to an extension of the I-beam 21. The piston rod -49 of the actuator is connected to an elongated slide 50 (FIG. 9) paralleling; the rails and slidable lengthwise of the -frame between guides 51 secured to the upper edges of the supporting bars 25. To convert reciprocatory motion of the slide to lateral movement of the rails, links 52 are pivotally connected at opposite ends to the slide and to the respective rails at spaced points along the rails. With .this construction, the rails are shifted away from and toward each other re- 4 spectively as an incident to advance and retraction of the slide.

In the four panel construction of FIG. 3, the inner and outer rails 26a and 26h are mounted and actuated the same as in the two panel construction. To utilize movement of the inner rails to eiect the clamping of the brick of Iall four panels, the intermediate rails 26e are mounted for movement longitudinally of the supporting bars 25. Herein, each of the intermediate rails is formed as onehalf of a bar 53 of channel cross section with parallel upstanding legs and a horizontal cross leg mounted on the supporting bar-s to slide along the top edges of the bars. Such mounting may be similar to the mounting of the inner rails 26a including bolts (not shown) depending rigidly from the channels at spaced points along the channels and rotatably supporting rollers for engagement with the undersides of adjacent supporting bars. As in the case of the inner :rails as shown in FIG. l0, the faces of the intermediate rails may have diierent contours.

While the end bricks 17 Vin the row supported on the bars 25 to form each panel themselves may constitute end dams co-operating with the side rails 26 and the inatable tubes 27 to limit the flow of grout, separate dams 54 are provided in this instance. Each of these, as shown in FIGS. l2 and 13, comprises an angle bar 55 of L-shaped cross section with a mounting block 56 depending rigidly from a horizontal leg and adapted to it between adjacent supporting bars 25 to maintain the other leg in an upright position. The ends of the upright leg are complementary in shape to the cross section of the side rails so as to provide an effective seal with the dam clamped between the rails, the upright leg herein having a resilient facing 57 to effect such a seal in spite of slight variations in the dimensions of the parts.

In the casting of panels using the improved jig construction, brick 17 are laid on adjacent pairs of supporting bars 2S as shown in FIG. 12 with one row of brick between each pair of side rails 26 While the side rails are retracted and the inflat-able tubes 27 are deilated, the spaces between adjacent brick registering with the spaces between the bars occupied by the tubes. Next, the end dams 54 are inserted and the iuid pressure actuator 47 is energized to shift the movable inner side rails 26a toward the outer fixed rails 2Gb. In the two panel jig of FIG. 1, this results in clamping of the inner and outer rails against the brick in the two rows between the pairs of rails. In the four panel jig, the inner rails engage the adjacent ends of the inner two rows of brick and the latter press against the intermediate rails 26C to clamp the outer rows of brick against the outer rails. With the brick thus held against the supporting bars and in their final desired positions, the tubes 27 are inflated so as to press upwardly into sealing engagement with adjacent lower edges of adjacent brick and with the side rails between adjacent brick. Then, the grout 18 is poured into the mold defined by the tubes, the rails and the dams and suitable agitator mechanism 58 (IFIG. 3) is operated to settle the grout, the vibrations ybeing absorbed by the resilient pads 24. Once the grout has hardened, the clamping pressure on the side rails is released and the tubes are deliated thereby leaving the finished panel free to be lifted away from the jig.

it will be apparent that, with the novel arrangement of spaced supporting bars 25 and intervening inflatable tubes 27, the improved jig may be adapted for building units of diiferent sizes simply by adjusting the spacing of the side rails Z6 and the locations of the tubes between the bars. By providing open spaces for the gravitation of foreign matter from the jig, the arrangement of bars and tubes also facilitates cleaning and maintenance of the jig. The common actuator 47 with the link connectors 52 for the movable inner rails 26a simplies the casting of two or more panels at the same time as well as reducing the parts and thereby the cost of construction of the jig.

We claim as our invention:

l. A panel casting jig having, in combination, a supporting framework including horizontally spaced parallel bars having upper edges lying in a common horizontal plane and adapted to engage and support the undersides of a plurality of building units arranged in horizontally spaced relation in four laterally spaced inner and outer parallel rows extending transversely of the bars, two horizontally spaced parallel outer rails extending across the tops of said bars and along the outer sides of the outer ones of said rows and secured to said bars, two intermediate rails extending across said upper edges of said bars between said outer rows and the inner rows and movable longitudinally of the bars, two inner rails extending across said upper edges of said bars between said inner rows of building units and movable longitudinally of the bars and away from each other to clamp the units of the inner rows against said intermediate rails and the units of said outer rows between the intermediate rails and said outer rails, said rails extending longitudinally of each other in generally parallel relation yand transversely of said bars, mechanism connected to said inner rails for shifting the same outwardly against the units of said inner rows, and tubes of exible material lying between said bars below the spaces between adjacent units in said rowsI and inflatable upwardly into sealing engagement with adjacent edges of adjacent units and with said rails between the units.

2. A panel casting jig having, in combination, a supporting framework including horizontally spaced parallel bars having upper edges lying in a common horizontal plane and adapted to engage and support the undersides of a plurality of building units arranged in horizontally spaced relation in four laterally spaced inner and outer parallel rowsl extending transversely of the bars, two horizontally spaced parallel outer rails extending across the tops of said bars and along the outer sides of the outer rows and secured to said bars, two intermediate rails extending across said upper edges of said barsI between said outer rows and the inner rows and movable longitudinally of the bars, two inner rails extending yacross said upper edges of said bars between said inner rows of building units and movable longitudinally of the bars and away from each other to clamp the units of the inner rows against said intermediate rails and the units of said outer rows between the intermediate rails and said outer rails, means between said bars cooperating With said rails and said units to conne grout poured between the units, and a single power actuator connected to said inner rails for shifting the latter simultaneously away from and toward each other to clamp and release all four of said rows.

3. A panel casting jig having, in combination, a supporting framework including horizontally spaced parallel bars having upper edges lying in a common horizontal plane and adapted to engage and support the undersides of a plurality of building units arranged in horizontally spaced relation in four laterally spaced parallel inner and outer rows extending transversely of the bars, two horizontally spaced parallel outer rails extending across the tops of said bars and along the outer sides of said outer rows and secured to said bars, two intermediate rails extending across said' upper edges of said lbars between said outer rows and the inner rows and movable ylongitudinally of the bars, and two inner rails extending across said upper edges of said bars between said inner rows of building units and movable ylongitudinally of the bars and away from each other to clamp the units of the inner rows against said intermediate rails and the units of said outer rows between the intermediate rails and said outer rails said rails extending generally parallel to each other and transversely of said bars, mechanism connected to said inner rails for shifting the 5 same outwardly against the units of said inner rows, and means between said bars cooperating with said rails and said units to contine grout poured between the units.

4. A panel casting jig having, in combination, a framework including horizontally spaced parallel bars having upper edges lying in a common horizontal plane and adapted to engage and support the undersides of horizontally spaced parallel building units with the untis arranged in parallel rows and the spaces between the bars and spaces between the units in registry, a pair of first horizontal rails extending transversely of said bars and secured to said upper edges of the bars in laterally spaced horizontal positions adjacent the outer ends of said bricks in said rows, a pair of second rails disposed between and paralleling said rst rails and mounted on said bars to move toward and away from the rst rails and into and out of clamping engagement with the inner ends of said building units and thereby clamp the units of each row between the adjacent flrst and second rails, a common actuator for said second rails, connections between said actuator and said second rails for shifting the latter simultaneously as an incident to operation of the actuator, and tubes of material impervious to bonding material lying between said bars in said registering spaces and inflatable so as to expand into sealing engagement with adjacent edges of adjacent building units and with said rails.

5. A panel casting jig having, in combination, a framework including horizontally spaced parallel bars having upper edges lying in a common horizontal plane and adapted to engage and support the undersides of horizontally spaced parallel building units with the units arranged in parallel rows and the spaces between the lbars and spaces between the units in registry, a pair of rst horizontal rails extending transversely of said bars and secured to said upper edges of the bars in laterally spaced horizontal positions adjacent the outer ends of said bricks in said rows, a pair of second rails disposed between and paralleling said first rails and mounted on said b-ars to move toward and away from the rst rails and into and out of clamping engagement with the inner ends of said building units and thereby clamp the units of each row between the adjacent rst and second rails, a common actuator for said second rails, connections between said actuator and said secton rails for shifting the latter simultaneously as an incident to operation of the actuator, and inatable means impervious to bonding material and movable upwardly between adjacent ones of said bars and into said registering spaces for sealing engagement with adjacent edges of adjacent building units and with said rails.

6. A panel casting jig having, in combination, a framework including horizontally spaced parallel bars having upper edges lying in a common horizontal plane and adapted to engage and support the undersides of horizontally spaced parallel building units with the units arranged in parallel rows and the spaces between the bars and spaces between the units in registry, a pair of rst horizontal yrails extending transversely of said bars and secured to said upper edges of the bars in laterally spced horizontal positions adjacent the outer ends of said bricks in said rows, a pair of second rails disposed between and paralleling said first rails and mounted on said bars' to move toward and away from the first rails and into and out of clamping engagement with the inner ends of said building units and thereby clamp the units of each -row between the adjacent rst and second rails, a common actuator for said `second rails, means between said bars cooperating with said rails and said units to contine grout poured between the units and connection between said actuator and said second rails for shifting the latter simultaneously as an incident to operation of the actuator.

(References 0n following page) References Cited in the le f this patent 2,017,587

UNITED STATES PATENTS 1,084,309 kmum 1311.713, 1914 2,917,801

2,250,020 Henderson July 22, 1941 5 2,460,167 .Carlsen Ian. 25, 1949 327 809 2,572,580 Almmfh et a1. oct. 23, 1951 577677 8f. Dennis Oct. 15, 1955 'Robinson Feb. 19, 1957 Kastenbein Oct. 14, 1958 Fitzgerald Dec. `22, 1959 FOREIGN PATENTS Italy July 18, 1935 Great Britain May 28, 1946 

